PRIORITY CLAIM AND REFERENCE TO RELATED APPLICATION
This application is related to and claims priority under 35 U.S.C. §119 from prior provisional application Ser. No. 60/690,202, which was filed Jun. 14, 2005.
FIELD
A field of the invention is displays. The invention provides a general purpose display device that is suitable for both large and small displays, such as those required by televisions, computer monitors, handsets, medical devices, etc.
BACKGROUND
Demand for flat panel displays is driven by a number of markets, including small and large consumer electronics applications, military applications, medical applications, handheld device applications, etc. Flat panel display sales have surged. The flat panel display market in 2004 was estimated by some to be a $62.2 billion market. Some expect this market to grow past $100 billion in a few years. In 2004, liquid crystal digital (LCD) displays accounted for about 78% of the $62.2B market.
Flat panel displays have obvious aesthetic and physical advantages compared to tube displays. Additionally, the picture quality in flat panel displays, e.g., plasma and liquid crystal digital displays has increased since the introduction of these technologies. Ongoing improvements in resolution and picture quality are being made, while the cost of flat panel displays continues to decrease.
In an LCD display, the positioning of a liquid crystal molecule column affects the polarization of light in a pixel. Each pixel in a display typically includes three sub-pixels. Each sub sub-pixel typically has one of three primary color filters (red, green or blue) and a black matrix. The display is backlit by a light source. Top and bottom polarizers are intended to block light when a sub pixel is “off”, and pass light to various degrees through the color filter when the electronics position the liquid crystal to polarize the backlight and permit it to pass through the color filter.
The LCD display model, while generally favored for low power, has some inherent drawbacks. The model relies upon two polarizer layers, which block a significant amount of light produced by the backlight. In the process of polarizing the light, the polarizer layer closest to the backlight blocks at least 50% of the light. Therefore, a large amount of electrical power is wasted to boost the light output from the backlight in order to produce a bright display. In portable electronics, e.g., laptop computers, personal digital assistants, and handsets, reducing the power consumption of the display remains important. The display, often an LCD display, remains the biggest single power draw in a typical portable electronic device.
Contrast, brightness and viewing angles are also issues in LCD displays. The relative lack of contrast and lack of brightness in LCD displays is attributable to the polarizer layers required by LCD displays. When a particular colored sub pixel is “on”, the polarizer layers permit the light to pass through the color filter and be emitted from the display, but the polarization filters portions of the available light and therefore substantially reduces the brightness of the light passing through. On the other hand, when a particular color sub pixel is “off”, the polarizer layers are intended to black the backlight, but effectively dim it to a great extent. An amount of light can be perceived as passing through the sub-pixel, reducing both the black levels and contrast ratios achievable with the LCD.
Recently, Philips has been researching and prototyping a different type of display, based upon the electrowetting principle. In the Philips prototype displays, electrowetting is used to move a colored oil layer away from a white background. The oil covers a hydrophobic layer, separating it from a water layer on top. Interaction of the oil, water, and the hydrophobic layer is controlled by an electric field. Application of an electric field across the layers causes water to contact the hydrophobic layer, displacing the oil, and the colored pixel is replaced by a white background.
Electrowetting is being researched by Philips and others, and various electrowetting display models have been published. U.S. Pat. No. 6,700,556, to Richley et al., entitled Display Sheet with Stacked Electrode Structure, discloses a display having alternating conducting and non-conducting sheets with fluid reservoirs. The reservoirs communicate with each other through apertures. Applying a field across selected apertures causes liquid to be pumped from one reservoir into the other, altering or producing a display based upon the position of the liquid. U.S. Pat. No. 5,956,005 to Sheridon, entitled Electrocapillary Display Sheet Which Utilizes an Applied Electric Field to Move a Liquid Inside the Display Sheet, also uses fluid movement between reservoirs for display effects.
U.S. Pat. No. 6,034,444 to Kawanami et. al., entitled Display Element and Display Device Having It, makes use of electronic control of liquid to focus or defocus light toward holes in a mask layer. In the '444 patent, first and second liquids are confined in a space between substrates. One of the liquids interacts with a patterned surface treatment layer. Under control of an electric field, the first liquid is controlled to have its contact angle with the patterned surface treatment layer changed. Light passing through the liquid is focused or not focused toward a corresponding small hole in the mask layer depending upon the contact angle of the first liquid.
U.S. Published application 2004/0196525 to Fujii et al, entitled Display Device discloses the use of fluid to either color or block light to produce a display. In the '525 application, a droplet of a coloring liquid is sealed in a cavity and controlled with an electric field to color or block light.
SUMMARY OF THE INVENTION
A light conductive controlled shape droplet display device of the invention includes a light source. A light conductive substrate receives and conducts light from the light source. A cover disposed relative to the substrate, conducts light received from the substrate out and away from the display device. Pixels in the display are defined by fluid droplets in optical communication with the substrate and the cover. Hydrophobic layers associated with the substrate and the cover control the shape of the fluid droplet in conjunction with properties of the fluid droplet. Persistent displays are possible, as are displays that require periodic refresh to maintain the display. Electrodes modulate the amount of light conducted by the fluid droplets from the substrate into the cover. In preferred embodiments, each pixel includes sub-pixels formed by different primary colored fluid droplets.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic cross-section showing a pixel of a preferred embodiment display device of the invention;
FIG. 2 shows a common plane electrode configuration for a modified embodiment display otherwise consistent with the display device of FIG. 1;
FIG. 3 is a schematic cross-section showing a pixel of another preferred embodiment display device of the invention;
FIG. 4 shows a preferred electrode configuration for the display device of FIG. 3;
FIG. 5 is a schematic cross-section showing a pixel of another preferred embodiment display device of the invention; and
FIG. 6 is a schematic cross-section showing a pixel of another preferred embodiment display device of the invention
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention provides a display device. A display device of the invention produces displays by controlling the shape and, in some embodiments the position, of fluid droplets using the electrowetting effect. The display includes an array of pixels, each having, for example, three sub pixels. In an individual pixel or sub pixel, a fluid droplet serves as an electrically controlled waveguide between a light guiding substrate and a display cover. The shape/position of the fluid droplet is controlled its fluid properties, by hydrophobic properties of layers that it contacts, and applied voltage. In preferred embodiments, the amount of light conducted through the fluid droplet depends on the shape of the fluid, permitting use of the shape to achieve a full range of light modulation in the pixel(s) or sub-pixel(s). In other embodiments, droplet position is used in addition to droplet shape to achieve a full range of light modulation.
A preferred embodiment light conductive controlled shape droplet display device of the invention includes a light source. A light conductive substrate receives and conducts light from the light source. A cover disposed relative to the substrate conducts light received from the substrate out and away from the display device. Pixels in the display are defined by fluid droplets in optical communication with the substrate and the cover. Hydrophobic layers associated with the substrate and the cover control the shape of the fluid droplet in conjunction with properties of the fluid droplet. Persistent displays are possible, as are displays that require periodic refresh to maintain the display. Electrodes modulate the amount of light conducted by the fluid droplets from the substrate into the cover. In preferred embodiments, each pixel includes sub-pixels formed by different primary colored fluid droplets.
Preferred embodiments will now be discussed with reference to the figures. Schematic illustrations will be fully understood by artisans. Artisans will also appreciate and understand that devices are not illustrated to scale, and features may be exaggerated for purposes of illustrating the invention.
FIG. 1 illustrates a portion of a preferred embodiment display device 10. FIG. 1 shows a single tri-color pixel 12 that includes separate sub pixels 12 a, 12 b and 12 c. The separate sub pixels 12 a, 12 b and 12 c have the ability to emit (or reflect) an individual primary color, e.g., red, blue and green. Additionally, the intensity of the emission by each of the separate sub pixels 12 a, 12 b and 12 c can be individually controlled. Whether a display is produced and the intensity of a display from each of the sub pixels 12 a, 12 b and 12 c is controlled by the shape of a corresponding light conducting fluid droplet 14 a, 14 b or 14 c. The intensity of display and whether or not a display is produced depends upon the angle F that the fluid droplets make with respect to a substrate 16 that conducts light rays 18 from a light source 20. The shape of the droplets 14 a, 14 b and 14 c is electrically controlled through the electrowetting effect.
Emissions from the sub pixels 12 a, 12 b and 12 c exit the display device 10 through a cover 22. Color filters can be used, or in other embodiments, the fluid droplets 14 a, 14 b and 14 c may also act as color filters in addition to providing the light conduction control that permits modulation of the display in a given pixel or sub-pixel. In the display device 10 shown in FIG. 1, the respective droplets 14 a, 14 b and 14 c are respectively different primary colored fluids that act both as controlled waveguides that selectively conduct light between the substrate 16 and cover 22, and also as color filters that filter the light being conducted between the substrate 16 and the cover 22.
In the display device 10, the contact angle F of each droplet 14 a, 14 b and 14 c is controlled by the potential between a common transparent electrode 24 and respective transparent electrode control lines 26 a, 26 b and 26 c. Hydrophobic layers 28, 30 contact the fluid droplets 14 a, 14 b and 14 c.
The fluid droplets 14 a, 14 b and 14 c, along with the hydrophobic layers 28 and 30, are selected to have appropriate viscosity and surface tension properties such that the droplets redirect light into the substrate 16 when no voltage is applied between respective electrode control lines 26 a, 26 b or 26 c and the common transparent electrode 24. This is the condition of the droplet 14 c in FIG. 1, which exhibits the greatest angle F with respect to the substrate 16. The electrowetting effect is used to change the shape of particular individual fluid droplets and can therefore be used to modulate the amount of light emitted by each sub pixel 12 a, 12 b and 12 c through the cover 22. Specifically, Snell's law can be used to show that most of the light conducted into the droplet when in the condition shown by the droplet of 14 c will escape prior to reaching the cover 22. Accordingly, when the sub pixel 12 c is viewed from above the cover 22, it will appear dark.
Application of a voltage between a respective transparent electrode control line 26 a, 26 b or 26 c and the common transparent electrode 24 causes the angle F to decrease through the electrowetting effect. The reduction in the angle F between a droplet and the substrate 16 changes the shape of the droplet and makes it a better conductor of light to be seen from above the cover 22. The conduction of light is inversely proportional to the angle F, and accordingly increases as the voltage and angle F increase.
Voltage can be varied between no voltage and a maximum voltage to vary the intensity of light displayed by each sub pixel 12 a, 12 b and 12 c as seen from the top of the cover 22. The pixel 12 is easily replicated in a large format array, as artisans will appreciate. Accordingly, the structure of the display device and of FIG. 1 can be used for a wide variety of display device applications.
The hydrophobic layers 28 and 30 and the fluid properties of the droplets 14 a, 14 b, 14 c can be adjusted to have no display in a no voltage condition or to have a display in a no voltage condition. The display device 10 of FIG. 1 has the surface tension balanced in a no voltage condition such that under the no voltage condition, the droplet has the shape of the droplet 14 c. When a voltage is applied between one or more of the transparent electrode control lines 26 a, 26 b, 26 c in the common transparent electrode 24, charge accumulates at the droplet-dielectric layer. The dielectric layer 32 insulates the transparent electrode control lines 26 a, 26 b and 26 c from the accumulated charge.
The hydrophobic layers 28 and 30 are not thick enough to provide electrical insulation in the FIG. 1 embodiment. The fluid droplets 14 a, 14 b, 14 c therefore make electrical contact with the common electrode 24, and the dielectric layer 32 electrically insulates the transparent electrode control lines 26 a, 26 b, 26 c from the fluid droplets 14 a, 14 b, 14 c to enable use of the electrowetting effect. In an alternate embodiment, the hydrophobic layer 30 is made thick enough to act as a dielectric, in which case the separate dielectric layer 32 can be omitted.
With respect to each droplet, the volume of fluid is constant, and the application of voltage causes a droplet to spread out more at the hydrophobic layer 30 associated with the cover 22, which pulls fluid away and decreases the angle that the droplet makes with the substrate 16. At maximum voltage, a droplet makes the smallest possible contact, as represented by the droplet 14 a in FIG. 1.
The substrate 16 has a higher index of refraction than surrounding environment, so a portion of light generated by the light source 20 is confined within the substrate 16 by total internal reflection. When droplets 14 a, 14 b and 14 c having a refraction index higher than the surrounding environment optically contact the substrate 16, the droplet acts as a conductor of light from the substrate 16 to the cover 22, and the amount of light conducted depends upon the droplet shape.
In the path of light from the substrate 16 through the waveguide droplets 14 a, 14 b, 14 c and out the cover 22, there is no substantial reduction of brightness as is inherent to the polarization that is required in LCD displays. The front emitting nature of the display 10 of FIG. 1 can also provide a wide viewing angle, the display has a relatively low part count that can contribute to a low manufacturing cost, can be fabricated into very large and very small arrays, and will have many other advantages that will be recognized by artisans.
Artisans will also recognize that various materials can be used to fabricate the display device 10 of FIG. 1. As an example, electrodes may be formed of indium tin oxide (ITO), a widely used transparent conductor, and the hydrophobic layers can be a material such as Teflon®. The substrate 16 and cover 22 can be formed of glass, and a cold cathode fluorescent lamp is a suitable as the light source 20. Many types of ionic fluids may be used to form droplets 14 a, 14 b, 14 c, and examples include water, ethylene and glycol. Dyes can be used to color fluids, or separate color filters can be used.
FIG. 2 illustrates an electrode configuration that can be used to modify the display device 10 of FIG. 1 to consolidate the common transparent electrode 24 and the transparent electrode control lines 26 a, 26 b and 26 c onto the top cover 22. In such a modified embodiment, the substrate 16 need only be coated with the hydrophobic layer 28. In FIG. 2, the reference numbers from FIG. 1 used to label the transparent electrode control lines and the common transparent electrode are labeled with the same numbers in FIG. 2 although they have the configuration as shown in FIG. 2. The fluid droplets 14 a, 14 b, 14 c, when used with an electrode configuration as shown in FIG. 2, will be aligned under circular electrode terminals 34 a, 34 b and 34 c that are formed at terminal end points of the common electrode 24. The dielectric layer 32 (see FIG. 1) under the circular electrode terminals 34 a, 34 b and 34 c is removed to permit fluid droplets to make electrical contact with the circular electrode terminals 34 a, 34 b and 34 c. The droplets are positioned directly under the circular electrode terminals 34 a, 34 b and 34 c. Application of a voltage potential between the control lines 26 a, 26 b, 26 c and the common electrode causes the fluid droplets to change shape in the same manner as in FIG. 1 when the electrode configuration of claim 2 is used.
With the display device 10 of FIG. 1 and the modified embodiment realized with the electrode configuration shown in FIG. 2, maintaining a display requires the maintenance of a voltage between the common transparent electrode control lines without application of voltage. When no voltage is applied, the fluid droplets return to the state of the fluid droplet 14 c as shown in FIG. 1, in which the sub pixel appears dark, when viewed from the top cover 22. The fluid may be selected such that the relaxation time is long, or alternatively, if the circuit capacitance is fairly high, a refresh voltage rate can occur during regular frame updates. If the decay rate of the fluid droplet shape is too quick given the refresh rate and other properties of the display, active thin film transistors can be used in a comparable manner to LCD displays to maintain the voltage between the common electrode 24 and the transparent electrodes 26 a, 26 b, 26 c. An alternative embodiment is a persistent display in which the display is maintained despite the absence of a potential difference between common electrodes and electrode control lines 26 a, 26 b, 26 c.
FIG. 3 shows a persistent display device 40 in accordance with another embodiment of the invention. The display device 40 of FIG. 3 uses like reference numerals to label parts that are comparable to those shown in the display device 10 of FIG. 1. In the display device 40 of FIG. 3, both the shape and position of fluid droplet 14 a, 14 b and 14 c are used to modulate the display of a given pixel or sub pixel. Each sub pixel 12 a, 12 b and 12 c includes a pair of dual electrode control lines 42 n, 44 n. At least one of the control lines in each of the sub pixels is transparent, and in FIG. 3, both are shown as transparent and the control lines 42 a, 42 b and 42 c include a black mask 46 a, 46 b, 46 c, disposed between them and the cover 22. The properties of the fluid droplets 14 a, 14 b and 14 c and the hydrophobic layers 30 and 28 in the display device 40 of FIG. 3 are set to control the shape of the droplets such that the droplets 14 a, 14 b, 14 c are permanently shaped to conduct the maximum amount of light to be seen from above the cover 22.
One way of accomplishing this is to make the hydrophobic layer 30 less hydrophobic than the hydrophobic layer 28. Application of a potential between one of the dual electrodes 42 n, 44 n with respect to the common electrode 24 moves the droplet toward one of the electrodes 42 n, 44 n. In FIG. 3, each of the droplets 14 a, 14 b and 14 c is shown in a different location. The droplet 14 a conducts the same amount of light as the other droplets towards the cover 22, but has its light output masked by the black mask 46 a. The droplet 14 b has only a part of it output to the cover 22 blocked by the black mask 46 b, and the droplet 14 c has none of its output blocked by the black mask 46 c. Once a droplet has been positioned, the display in the respective pixel or sub-pixel is persistent without further application of voltage. A voltage pulse to effect the display of a particular sub pixel need only be sent when the display is to be changed from a current state.
In the display of FIG. 3, the incremental movement of the shaped fluid conducting droplets 14 a, 14 b and 14 c modulates the amount of light emitted from each sub pixel 12 a, 12 b and 12 c. FIG. 4 shows an electrode control line pair configuration, in which control lines 42 a and 44 a include jagged interlocking terminals 48 a and 50 a. The incremental movement of fluid droplets can be more precisely controlled with the terminals 48 a, 50 a shown in FIG. 4, which can be used to produce a higher resolution display device.
A variation of the FIGS. 1 and 3 embodiments uses a single fluid droplet to produce all three primary colors sequentially. Such a variation can be employed if the shape and/or condition can be changed rapidly compared to the frame rate. One way to achieve such a variation of the FIGS. 1 and 3 embodiments is to change the color of the light from the light source 20 sequentially such that there are sequential primary color phases, e.g., red, green, blue phases. In that case, a tri-color pixel may be realized with a single pixel that has its level of light conduction changed in either or both of the manners illustrated with respect to the devices 10 or 40 in FIGS. 1 and 3. The sequential color control would be similar to the micro mirrored style projection displays.
FIG. 5 shows another embodiment display device 52 that shows the cover 22 modified to include cone structures 54 a, 54 b and 54 c. The cone structures 54 a, 54 b and 54 c are an example of a structure that can be formed in the cover or the substrate 16 to enhance fluid droplet shape and position control resolution as a function of applied voltage. Other parts of the display device 52 that are similar to parts shown in the display device 10 of FIG. 1 are labeled with like reference numbers. In the display device 52 of FIG. 5, application of a voltage in a particular sub pixel 12 a, 12 b and 12 c causes a respective droplet 14 a, 14 b or 14 c to stretch and cover its respective cone 54 a, 54 b, 54 c. The maximum conductive state for the fluid droplet waveguide is illustrated by the droplet 14 a. A lack of applied voltage results in the shape of the fluid droplet 14 c, which is repelled by the hydrophobic layer 30 on the cone 54 c, which will cause the pixel 12 c to appear dark. The shaped structures 54 a, 54 b and 54 c provide more surface contact area with respect to the hydrophobic layer 30, and therefore provide potentially finer control over the intensity of each of the sub-pixels 12 a, 12 b and 12 c.
Structures can also be introduced into the substrate 16, as illustrated by the display device 56 shown in FIG. 6. Small structures can be etched around into the substrate 16 or the cover 22. In FIG. 6, scattering structures 58 a, 58 b and 58 c formed on the substrate 16. The scattering structures 58 a, 58 b and 58 c scatter light in the substrate 16 that would otherwise be trapped through internal reflection. The scattering structures 58 a, 58 b and 58 c can be designed such that most of the scattered light is visible through the cover 22. With respect to an individual sub pixel, no voltage causes a fluid droplet to be repelled from a respective scattering structure, as illustrated by the droplet 14 a and the scattering structure 58 a. In this case, maximum light is visible for the sub pixel 12 a. Increasing the voltage potential in a particular sub pixel to the maximum state illustrated for the sub pixel 12 c causes the droplet 14 c to fill the scattering structure 58 c. In that state, the scattering structure 58 c becomes indistinguishable from the fluid 14 c and no light is scattered by the scattering structure 58 c to create a dark pixel. The intensity of the sub pixels is modulated by the extent of the fluid that holds the scattering structures in the FIG. 6 embodiment.
Artisans will recognize many other variations consistent with the shape and, in some embodiments, position control of the exemplary display devices illustrated by the preferred embodiments. Artisans will recognize that standard micro fabrication and circuitry fabrication techniques can be used to form display devices of the invention. Fluid droplets may be positioned in a number of ways, including, for example, by ink jet printing techniques or by dipping patterned hydrophobic layers into solution. For example, the hydrophobic layers can be lithographically patterned with photoresist and developed. The unprotected hydrophobic material can be etched away either chemically or via plasma etching. Once the photoresist is removed, the hydrophobic layer will resemble the original lithographic mask, with precise areas covered by hydrophobic material. When dipped into a solution, areas without hydrophobic material will attract the solution and areas with hydrophobic material will repel the solution. This method allows droplets to assemble in precise locations across a large area quickly.
While various embodiments of the present invention have been shown and described, it should be understood that other modifications, substitutions and alternatives are apparent to one of ordinary skill in the art. Such modifications, substitutions and alternatives can be made without departing from the spirit and scope of the invention, which should be determined from the appended claims.
Various features of the invention are set forth in the following claims.